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Service Booklet Service-Handbuch Scrubmaster B 120 R (7177.XX) Schulung/Training Fehlersuche/Troubleshooting Einstelldaten/Adjustments Hako GmbH Technisches Produktmanagement 23840 Bad Oldesloe, Germany Updated 05/2018 - Rev.1.03 Confidential – for internal use only Sheet 1...
Table of contents Information General information 2.1 Settings 2.1.1 Connecting to the diagnostics PC 2.1.2 Flashing the control unit 2.1.3 Connection diagram 2.2 Brief description 2.2.1 Switching off vacuuming / dirt water tank full 2.2.2 Indication Solution Tank empty 2.2.3 Machine home position 2.2.4 Seat contact switch (3.6.6.4.) 2.2.5 Accessing programming 2.2.6 Resetting the last service message in the switch-on menu...
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Table of contents Maintenance intervals 4.1 Hako system maintenance (customer) 4.2 Hako system maintenance I 4.3 Hako system maintenance II 4.4 Hako system maintenance S Cleaning programmes (FPV) Machine settings 6.1 Basic settings 6.1.1 Cleaning units 6.1.2 Battery and charger settings 6.1.3 Battery setting (LDS)
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Table of contents Mechanical components 7.1 Squeegee 7.2 Rotating brush heads 7.3 Roller brush heads 7.4 Lifting element brush head 7.4.1 Potentiometer in the lifting element for the brush head Water pump 8.1 Water quantities 8.2 Water pump standstill detection Drive 9.1 DMC drive control (AC motor) 9.1.1 Connection description...
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Table of contents Service messages 10.1 Service alarm clock 3.3.1.1 Battery charger 11.1 Operating manual 11.2 Programming the charger 11.3 Charge data table Options Real-time clock (RTC) Notes Sheet 5...
1. Information Caution: • During all work at the machine, secure it against unintentional movement. • Only carry out work at the machine when it has been de-energised (disconnect the battery plug), except for current and voltage measurements. • After repairing electrical drives, measure the starting and operating currents to detect possibly still present errors.
2. General information The Scrubmaster B120 R is equipped with a service indicator in the display of the operating hours meter. When switching on the key switch, four digits are shown on the display for approx. 3 seconds that state the software version (e.g. 1.004), and possibly further four digits that show the last displayed service message, followed by the hour indicator.
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2. General information Scrubmaster B120 R The Scrubmaster B120 R is available in working widths of between 70 cm and 90 cm. The machines are always supplied ex factory with batteries; here, it is possible to choose between various battery sizes (from 180 Ah to 320 Ah) as well as between different battery technologies (EPzS/EPzB, PzV or GiV).
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2. General information Configuration machines are manufactured order-specifically according to customer wishes from a pool of available equipment features. Additional options (chemical dosing, working light, warning signal, etc.) are installed in the factory. For more details, see the relevant current price lists. Sheet 9...
2.1 Settings Respective settings can be carried out via the machine’s configuration menu. Currently, these settings are carried out via the machine display. The diagnostics plug (order no. PN 03006790) is required for these settings. Setting via the diagnostics system is planned but currently not yet available. Settable parameters include: •...
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Therefore, the machine software must be “flashed” onto the central control unit after mechanical installation and electrical connection of the central control unit. • Service PC on which the current HAKO diagnostics software is installed. (Windows 7 or higher) •...
2.1.1 Connecting to the diagnostics PC The following components are required to activate the control unit of the Scrubmaster B120 R after a replacement: • Current Hako diagnostics software (via the Hako WebX download portal) • Service PC (e.g. Panasonic CF19 / CF20) •...
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2.1.1 Connecting to the diagnostics PC Download the “HakoDiagnostics” software as a zip file or as a folder from the Hako WebX download area. Information on accessing the download server can be requested from Maike Christiansen, e-mail: mchristiansen@hako.com. To install the software on a service computer or for Updating it: Follow the instructions in the HakoDiagnose MainSetup Guide, delivered with the Diagnosis software.
2.1.2 Flashing the control unit • Install the control unit –A01 fully in the machine, activate the backup battery. To do so, remove the insulating strip between the battery (CR2032) and the battery holder on the rear of the control unit. •...
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7-pole round plug) included in the scope of delivery of the diagnostics cable. Flashing the software: Turn on the machine. Start the Hako diagnostics software. Select the “HAKO” button, then click the “Scrubmaster B120R” button. The application independently searches for a new, blank control unit.
2.1.3 Connection diagram OBDII Cable D-Sub9-Con- PN 03502750 nector„RS232“ CAN-Fox Interface PN 03502430 * D-Sub9-Socket OBD-plug, to „CAN2“ - BLACK the Machine USB-plug, to the D-Sub9-Connector D-Sub9-Socket Service PC „CAN“ „CAN1“ - RED Sheet 16...
2.2 Brief description Machine control takes place with the following electronics: • Central electronics (A1) • Control and display panel (A2) • Drive control (A4) • Chemical dosing (A101) The control electronics (A1) assumes all control and monitoring tasks in the machine except for the drive functions.
2.2.1 Switching off vacuuming / dirt water tank full Vacuuming is switched off by the operator via the tip switch or automatically in case of the signal “dirt water tank full” to protect the suction turbine. Switching off by the operator: •...
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2.2.1 Switching off vacuuming / dirt water tank full Switch off at recovery tank full: The indicator switch for recovery tank full, is in the B120R a differential pressure sensor. As soon as the little ball in the filter sieve is lifted up by the water level and then sucked, the airflow to the suction motor is interrupted.
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2.2.1 Switching off vacuuming / dirt water tank full Sheet 20...
2.2.2 Indication Solution Tank empty As soon, as a amount of approx. 10l water is left in the solution tank, the machine control system indicates it with a blinking water tap and a acoustical signal. This is determined by a float switch, that is positioned in the solution tang in the area above the right rear wheel.
2.2.3 Machine home position After turning on the machine, all components are set to “home position” if the seat contact switch is actuated (closed). The lifting elements will be raised if they have not already been switched off via the micro-switch for the upper end position integrated in the lifting element (squeegee) or the upper end position is detected by the control unit via the integrated potentiometer.
2.2.4 Seat contact switch (3.6.6.4.) The seat contact switch (S05) is connected to the control electronics A1 at A1:X9.8+18 and A1:X9.3+13. The control electronics (A1) responds to the relief of the seat with an approx. 2 second delay. This means: If the contact at A1:X9.8+18 is opened for longer than 2 seconds during machine operation, the motors stop and the brush head and the squeegee are raised.
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2.2.4 Seat contact switch (3.6.6.4.) To reactivate the machine after triggering “seat switch manipulation”, the machine control unit must “register” the change of the switch status or the change between ‘operator is sitting on the machine’ and ‘operator has left the seat’. To achieve this, the seat contact switch must be opened and closed several times while the machine is on.
2.2.5 Accessing programming The Scrubmaster B120R can be configured via the software and adapted to various options. The machine is also adapted to the different hardware (machine type, rotating brush head or roller brush head, batteries – LDS charger) via the software. Changes to parameters not described in this manual can result in the machine malfunctioning.
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2.2.5 Accessing programming A01.X3 Simultaneously press and hold tip switches 1 and 2 (Fig. 2.3) and switch on the key switch. The following display is shown in the operating hours meter after approx. 3 seconds: Figure 2.1 •You are now in the start menu of the configuration.
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2.2.5 Accessing programming Navigation in the configuration menu takes place using the three marked tip switches of the control panel. Tip switch 1 for “water+-”; tip switch 2 for “water on/off”; Control panel tip switch 3 for “chemical dosing” (Fig. 2/3). The configuration menu is presented by three numbers (Fig.
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2.2.5 Accessing programming The active level is changed by pressing tip switch 1: Chapter -> Configuration -> Content -> Chapter Chapter Configuration Content The value of the active level is increased by pressing tip switch 2. Once the highest value has been reached, it is returned to the lowest value.
2.2.6 Resetting the last service message in the switch-on menu Access to the programming level as described in Chapter 2.2.4. Figure 2.1 is displayed. The diagnostics plug must be connected to A1.X3 for changing parameters. Without the diagnostics plug, the parameters cannot be changed. Press tip switch 2 six times to show the last occurred error on the display, e.g.
4. Maintenance intervals The Hako system maintenance specifies in single modules the special technical work to be done and the periods of time for the maintenance activities. Parts to be replaced for the individual maintenance tasks are determined. Further details are also listed in the respective chapters.
4.2 Hako system maintenance I Maintenance must be carried out by an authorised Hako service workshop at the following maintenance intervals. Sheet 37...
4.3 Hako system maintenance II Maintenance must be carried out by an authorised Hako service workshop at the following maintenance intervals. Sheet 39...
4.4 Hako system maintenance S (safety check) Maintenance must be carried out by an authorised Hako service workshop at the following maintenance intervals and at least once a year. Sheet 40...
Cleaning programmes (FPV) The cleaning programmes are used to specify the behaviour of the water supply to the brushes, the brush motors in relation to the position of the driving direction switch and the drive potentiometer (forwards, neutral, reverse) as well as the squeegee. A GND signal via XS11 is set to the input of the driving direction switch at A02.X6:4 via the drive potentiometer switch in B03.
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5. Cleaning programmes (FPV) Content Function Brush off when drive control is in neutral Brush off when drive control is in reverse Lift brush when drive control is in neutral Lift brush when drive control is in reverse Water off when drive control is in neutral Water off when drive control is in reverse...
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5. Cleaning programmes (FPV) Description Eingestellte FPV Refer to FPV table Refer to FPV table Refer to FPV table Refer to FPV table Refer to FPV table Refer to FPV table Refer to FPV table Refer to FPV table Refer to FPV table Table 5.2 Sheet 43...
6. Machine settings 6.1 Basic settings The machine series Scrubmaster B120R offers different equipment options and working widths. These can be set and adapted in the configuration menu. To check and change the setting, access the programming level as described in Chapter 2.2.4.
6. Machine settings 6.1 Basic settings 6.1.1 Cleaning units Four different brush units are used with the Scrubmaster B120R. Two plate brush units with a working width of 75 cm or 90 cm; as well as two cylindrical brush units with a working width of 70 cm or 85 cm. This setting is necessary for correct functioning of the overload limits and water quantities.
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6. Machine settings 6.1.1 Cleaning units Description Brush decks Plate brush deck 750mm Plate brush deck 900mm Cylindrical brush deck 700mm Cylindrical brush deck 850mm Adjustment for work with Pads 1) Available on from Software revision 1.005 Table 6.1 Sheet 46...
6. Machine settings 6.1.2 Battery and charger settings In order to achieve optimum service life and performance of the batteries available for the machine, it is necessary to set the battery monitor, called LDS, and the charger to the correct battery type and capacity. These settings are carried out in the menu items 0.3.X;...
6. Machine settings 6.1.3 Battery setting (LDS) GiS and GiV are batteries with grid type plates PzS and PzV are batteries with tubular type plates GiV and Pzv are encapsulated, absolutely maintenance-free gel batteries GiS and PzS are sealed, low-maintenance batteries containing liquid electrolyte Regular checking of the electrolyte as well as topping up cleaned water are required here.
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6. Machine settings 6.1.3 Battery setting (LDS) Description TSG Adjustment - Battery-Type (only for 0.4.0; 0.4.1 and 0.4.2) Crown w/o Offset Crown GIS, „Foreign“ PzS or PzB „Foreign“ PzS or PzB AGM - only for Hoppecke batteries Table 6.2 Sheet 49...
6. Machine settings 6.1.4 Charger In this menu item (0.4.X), it is specified whether the machine features an integrated charger and whether this charger communicates with the machine control unit via CAN bus. With chargers that communicate with the machine, there are various selection options. If the charger with free characteristic curve selection is selected, the correct characteristic curve must be determined using the charger documents and then set correctly under 0.5.X.
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6. Machine settings 6.1.4 Charger Description Battery charger and Battery types w/o battery charger battery charger w/o communication Battery charger with communication (manual charging characteristics selection)-see battery charger manual Battery charger with communication for GiV-batteries Battery charger with communication for PzV-batteries Battery charger with communication for PzS/PzB-batteries Table 6.3 Sheet 51...
6. Machine settings 6.2 Customer-specific settings (PPV) Different settings can be carried out at the machine using the programmable programme variants. It can, e.g., be set whether the last error that occurred in the machine is shown when turning on the machine or not. To check and change the setting of the PPV, access the programming level as described in Chapter 2.2.4.
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6. Machine settings 6.2 Customer-specific settings (PPV) Description Last error indicator after switching on the machine Deactivate Activate Water level when switching on scrubbing Last setting Preset level (4) Water level when switching on scrubbing and vacuuming Last setting Preset level (4) Sheet 55...
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6. Machine settings 6.2 Customer-specific settings (PPV) Description Water level when switching on TOOL (menu option only appears when TOOL option is activated!) Last setting Preset level (4) Water Setting From last level to first level (in circuit) Change direction on reaching max./min. level (ping-pong) Silence Mode Setting Is not saved Is saved...
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6. Machine settings 6.2 Customer-specific settings (PPV) Description Acoustic Alarm Tone Interval (menu option only appears when the Acoustic Alarm option is activated!) Standard Alternative Highest water stage independent from machine speed Sheet 57...
7. Mechanical components 7.1 Squeegee Squeegee connection Carry out the pre-setting of the threaded bar for adjusting the squeegee inclination using the dimensions shown in Fig. 7.1 while making sure that the side with the fine thread (M10x1) faces the rear towards the squeegee. Figure 7.1 Sheet 58...
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7. Mechanical components 7.1 Squeegee Adjusting the sealing strips / inclination The inclination adjustment decides whether the sealing strips of the squeegee are positioned evenly on the ground. 1. Place the machine on a level surface and lower the squeegee. 2.
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7. Mechanical components 7.1 Squeegee Height adjustment The height adjustment (X) of the supporting rollers Fig. 7.4 (A) has been set to 3 mm in the factory. If striping still occurs despite optimum inclination adjustment, set the distance of the supporting rollers to the lower edge of the sealing strip by adjusting the number of washers under the supporting roller holder.
7. Mechanical components 7.2 Rotating brush heads Rotating brush heads in two working widths (75 cm and 90 cm) are used with the Scrubmaster B120R. Both brushes are driven by a separate motor. 7.3 Roller brush heads Two working widths (70 cm and 85 cm) are available as roller brush units for the Scrubmaster B120R.
7. Mechanical components 7.4 Lifting element brush head Position of the lifting element when the brush deck is lifted. Fixing point for the Fixing point for the Position of the lifting Position of the lifting element for work with relieve spring of the relieve spring of the element with increased Plate- and Cylindrical...
7. Mechanical components 7.4 Lifting element brush head 7.4.1 Potentiometer in the lifting element for the brush head The lifting element for the brush head features integrated position detection. This position detection is supplied with 24 V via the machine’s key switch. The reference signal for the position of the brush head can be measured at the central control unit at A01.X19:2 + 3.
8. Water pump The water pump for supplying the operative units is connected at the central control unit at A01.X11:4 + 11. It is operated via clocked voltage to convey different water quantities for the six stages. The voltage values measured here depend on numerous factors; it is therefore not possible to specify exact values.
8. Water pump 8.1 Water quantities Measurement of the water quantities offers a good and reliable method to test correct functioning of the water pump. Let the pump run and measure the water quantity conveyed per minute. The water quantity for the plate brush units can be set from approx.
8. Water pump 8.2 Water pump standstill detection If the pump cannot convey freely because the water cannot run freely through the hoses to the brush, the so-called water pump standstill detection becomes effective. Automatic water pump standstill detection: The electronics offers the option to protect the water pump if the pump can no longer convey freely.
Drive The drive control features its own diagnostics and a self-test. Therefore, the function of the drive control is locked when turning on the machine if the drive potentiometer is in neutral or is not recognised as being in neutral. The same behaviour applies after the seat contact switch has opened and is closed again.
Drive 9.1 DMC drive control (AC motor) The DMC drive control features a diagnostics input. Unless clearly noted in the service documents, changes to the preset values and parameters is generally not permitted. Currently, only the diagnostics with flash codes for the LED indicator is used. 9.1.1 Connection description: M1;...
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Drive A1 – forwards (active when B- is connected) from A02:X6.2 A2 – reverse (active when B- is connected) from A02:X6.3 A3 – release for driving from drive potentiometer switch B03 (active when B- is connected) A4 – release from machine control unit (seat contact) (active when B- is connected) A5 –...
Drive 9.2 Service codes DMC control unit Code Name Description Remedy Controller warning faults - Reduces only performance - Fault will reset itself (if possible) Not used Low Voltage Low Battery voltage (U < 18V) Charge battery Not used High Battery Voltage (typically during High Voltage Defective Battery? Excessive downhill ride? braking) (U >...
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Drive 9.2 Service codes DMC control unit Code Name Description Remedy Drive error faults -Commences gracefull neutral brake - requires a neutral recycle action to reset fault Memory chip fault Memory not accessible Internal voltage <12V; replace Drive Control Unit Check the wiring of the direction switch 2 directions active forward and Reverse direction active...
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Drive 9.2 Service codes DMC control unit Code Name Description Remedy Soft error faults - immediately stops pulsing - Requires a neutral recycle action to reset fault Low voltage internal 12V supply too low Check charging level of the battery Not used Low voltage Battery voltage too low...
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Drive 9.2 Service codes DMC control unit Code Name Description Remedy Hard Error Faults - Immediately stops pulsing and open line contactor - Cannot be reset (only by a key switch recycle) Hardware over current trip Motor Over current Check Motor and Motor wiring Coil of Line Contactor or Magnetic Brake Check Line contactor (-K02) and Magnetic Contactor Coil driver fault...
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Drive 9.2 Service codes DMC control unit Code Name Description Remedy Hard Error Faults - Immediately stops pulsing and open line contactor - Cannot be reset (only by a key switch recycle) Faulty current measuring Current measuring circuit defect Replace the Drive Control Unit Mosfet shortcircuited to battery minus Check insulating of the motor.
Drive Brake – manual release of the brake In order to also move the machine without power supply (no battery installed or other problems with the drive), the magnetic brake can be unlocked manually. In order to push the machine, carry out the following steps: 1.
Drive Brake – testing the brake function The brake must be capable of stopping the machine on a level road within 0.19 m per km/h. At a maximum speed of 6.5 km/h, this means that the maximum braking distance must not exceed 1.235 m.
Service messages Service-Code Description Remedy Output Brush motor Semiconductor failure or 1.2.2.1. Check brush motors and it´s wiring short circuit to battery plus Check current consumption of brush motors and wiring of the 1.2.5.2. Thermo switches brush motors thermo switches 1.2.6.1.
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Service messages Service-Code Description Remedy 1.4.6.3. Suction motor over current or short circuit Short circuit in the suction motor or in it´s wiring Water valve over current, interruption in the wiring or short 1.5.4.1. Malfunction water valve circuit to battery plus 1.7.4.1.
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Service messages Service-Code Description Remedy 3.3.1.1. Service intervall expired Reset the service intervall with the Hako diagnosis 3.3.4.1. Malfunction in the buzzer -P02 Over current or interrupted wiring Malfunction drive control unit; Magnetic brake 3.3.8.1. Check the magnetic brake and it´s wiring short circuit or interrupted wiring Malfunction drive control unit;...
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Service messages Service-Code Description Remedy 3.4.1.3. Malfunction drive control unit See blinking code at the drive control unit 3.4.2.1. Interruption power wiring drive motoer Check the wiring of the drive motor Malfunction drive control unit; over temperature See blinking code at the drive control unit; check the wiring of the 3.4.5.1.
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Service messages Service-Code Description Remedy CAN-Bus-error between machine control unit and drive 4.1.2.1. Communication problem drive control unit control unit 4.1.3.1. Communication problem drive control unit See blinking code at the drive control unit Communication between display and control unit interrupted 4.5.2.5.
Battery charger 11.2 Programming the charger The integrated Battery charger is adjusted to the different batteries only via the machine control unit. (see chapter 6.1.4 and 6.1.5) Sheet 89...
Options Both factory and field options are available for the Scrubmaster B120R series. The factory options are only available for new machines ex factory. The field options can be retrofitted in the machines. The parameters for the options that require a release via the machine’s control system are specified in Table 12.1.
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Options Description Silence-Kit not available available Warning Signal (Optical and acoustical) (Front, Rear and Beacon on Pole) not available available Chemical Dosing Agent not available available TOOL not available available Sheet 92...
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Options Description Working Headlight not available available Fleetrecorder not available available TOOL - Spinkle Nozzle (for cleaning of the recovery tank) not available available Sheet 93...
13. Real-time clock (RTC) Tip switch 5 Tip switch 6 The Scrubmaster B120R features a real-time clock integrated in the machine’s control system. When the machine is turned off, this clock is Control panel supplied with voltage via a backup battery on the control electronics.
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13. Real-time clock (RTC) • To access the options menu, press and hold tip switches 1 and 2 simultaneously while the key switch is switched on. The display for the year is shown in the operating hours meter after approx. 3 seconds.
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• After pressing tip switch 5 for 3 seconds, the changed value is saved and the bottom right dot behind the last number reappears. • Exit the menu by turning off the machine. • The settings can also be carried out via the Hako diagnostics system. Sheet 96...